contains basic knowledge of engine and different parts and system involved like fuel system, lube system, cooling system, combustion process, air system and circulation , working of external components of engine, reason and symptoms of wear of parts and components. This presentation is made to give the explanation of work done or things learnt during training in prestigious Gainwell Caterpillar.

1. Submitted by:
Savant Panwar
Submitted to:
Gainwell Commosales Private limited

2. Acknowledgement
• First of all I would like to express my gratitude towards the almighty that made this golden opportunity possible
and made me successfully completed it. I would like to thank my parents as without their support I would have not
been able to keep the momentum up.
• I am courteous to Mr. Reindeer Kr. Pandita Sir, Head Facilities and Mr. Vikas Copra Sir, Workshop Facility Manager
who's blissful support and enlightening guidance help me shaped overall, I am able to broom at my fullest and reach
the pinnacle under his umbrella. Also, I am deeply indebted to Mr. Alok Dhoundiyal, Engineer-Engine Assembly. And
Mr. Mohd. Munis sir for their intellectual, insightful, and experienced guidance that led me complete my Internship
Training Program on "Engine Disassembly & Assembly" held in the esteemed organization "Gainwell Commosales
Private Limited".
• Through this Internship Training Program, I gained precious exposure to the crucial industrial training as well as gain
and polish important skills and I am confident about that it will lead to me a brighter future and will help me outshine
the carrier.
• Lastly, I would like to thanks all the staff members that at somewhere during this training helped me out and let me
achieve my goal.

3. Unnati Workshop
• Major machines, engines, transmission, torque converter, and other
components of heavy Caterpillar machines or rebuild here.
• engine models ranging
• C 2.2, C 4.4, C 6.4, C 7.1, C7, C9, C11, C13, C15, C16, C18, C27,
C32, 3116, 3126, 3306, 3512, 3406 and others are rebuild and tested
here.
• It is equipped with diesel and gas engine test bench.

4. Agenda
• Engine Families
• Engine works & wears
• Engine Wear
• Combustion process
• External Components
• Cooling System
• Lube system
• Fuel system
• Air System
• Electronics
•
• Parts Differentiation

5. Click to add text

6. • Bore
• Stroke
• Compression Ratio
• Displacement
• Horsepower
Common Engine Terms

7. Bore Size
• Bore is the inner diameter of the
cylinder.
• Bore is measured in inches or
millimeters using Dial Bore Guage.

8. Stroke
• Stroke is the distance between
the TDC ( Top Dead Centre) and
BDC (Bottom Dead Centre) .
• Stroke is equal to twice the crank
radius.

9. Compression Ratio
• Compression Ratio is the ratio between the cylinder
volume with the piston at BDC and the volume with
the piston at TDC.
• Compression ratio of CAT engine are approximately
16:1 (non-ACERT) and 18:1 (ACERT).

10. Displacement
Engines size is expressed in liters or cubic
inches.

11. Horsepower
• Horsepower is the rate of doing work (how
quickly a force is applied through a distance.)
• Horsepower can be expressed in pound per
second.
• 1 horsepower = 550 lb./ft per second = 33.00
lb./ft per minute

12. Engine Model Numbers
• Engine model no. Is the code to tell
you the engine family, no. Of
cylinder, capacity, type of ignition
and so on.
• For example,
• 3208 Engine:
• 3200 = Engine family & relative
size
• (3000, 3200, 3400, 3500, 3600)
• 08 = no of Cylinders.
• Depending on Engine family, could
be 04, 06, 08, 12, 16, 18 or 24

13. Engine Wear
• Definition of wear
• 1. Contact
• 2. Pressure
• 3. Relative Motion
• Normal & Abnormal wear
• Major wear items
• Cylinder liners
• Seals & gaskets
• Piston rings
• Turbo bearings and seals
• Valves, guides, and seats
• Main and rod bearings

14. Combustion Process- 4 Stroke Cycle

15. Combustion Process- 4 Stroke Cycle

18. Valve Train
1. Cam lobe
2. Lifter
3. Pushrods
4. Rocker arms
5. Bridge (intake)
6. Valve Spring
7. Exhaust valve
8. Intake valves

19. Pistons, Rings, & Liners
• Cylinder liners
• O-ring seals
• Pistons
• Piston rings
• Piston pins and retainer

20. Piston assembly &
Connecting rod
• A connecting rod connects the piston to the
crank shaft.
• The Dome Piston looks just like it sounds.
Instead of a flat top it has a dome that looks
like the top of a dome stadium. Piston
Dome refers to the amount of added
volume on top of the piston compared to a
flat top piston.

21. Cylinder Head & Cam shaft
• The cylinder head is installed on
the top of block
• The cam shaft turns at ½ the
speed of the crankshaft to control
intake & exhaust operation.

23. Cylinder Block
• This cylinder block is the central component
of an engine
• It houses the components that make up the
serious nucleus of the engine

24. Turbocharger
• An exhaust driven air compressor.
• Impeller on the left
• Turbine on right
• Connecting shaft, free floating bearings,
oil lubricated center housing
Causes of Premature wear or failure
• Poor oil quality​
• Dirt injection
• Hot engine shut down​

25. Aftercooler
• Heat exchange of inlet air
• Series of metal tubes
through which hot inlet air
flows
• Heat from the air flowing
from the tubes is absorbed
through the tubes valves
and carried away
• 2types
Air to air (ATAAC)
Jacket water (JWAC)

26. Water Pump
• Flow of the coolant begins
at the water pump
• Pump impeller creates the
flow
• Water pump are gear or
belt driven
• Water pump seals
separates engine oil from
coolant

27. Oil Pump
• Engine coolant flows from the water
pump directly into the oil cooler
• Oil carries heat away from the critical
engine parts
• Heat is transferred from the oil to the
engine coolant

28. Oil Pump
• Oil coolant flows through the copper
tubes in the oil cooler housing
• Oil flows around outside of the tubes
• Scale build up caused by improper cooling
system maintenance can be cleaned out
of the tubes

29. Function of cooling system
• Maintain proper engine
temperature for optimum
performance.
• Dissipates excess
heat from other machine
system:
• Engine
• Transmission
• Hydraulic
• Cools compressed inlet air to
optimize combustion.
Function of cooling system

30. Cooling System components
• Water pump
• Oil Cooler
• Passages through block and head
• Temp. Regulator Housing
• Radiator
• Pressure Cap
• Hoses & pipes

31. • Coolant flows around
cylinder liners
• Absorbs heat from
combustion chamber
• Prevents breakdown of oil
film between piston and
liners
Cooling Systems

32. • Cleans
o Parts
o Cylinder walls
• Cools
• Seals & Lubricates
o Support
o Separate
Function of Lubrication System

33. 1. Oil Pump
2. Relief Valve
3. Oil Cooler
4. Oil Filter
5. Bypass Valves
6. Oil Level Gauge (Dipstick)
7. Oil Pressure Gauge
8. Oil Pan
Lubrication System Components

34. Causes of Lube System Wear & Failure
• Single largest problem is short engine life due to excessive
soot in the oil.
• Poor quality/low performance engine oil
• Extended oil change intervals
• Poor maintenance practices
• Fuel dilution
• Wear (lube System Caused)
Seals/Bearings
Turbo
Crank – Main/Rod
Valve, Guide

35. Methods to control soot levels in
engine oil:
• High quality engine oils contain
effective soot dispersant
additives
• High performance, full flow, lube
filter options
• Standard, Advanced,
& Ultra-High
• Bypass filtration devices:
centrifugal or barrier filters
• Oil renewal systems (for large
mining machines)
Methods to control soot levels in engine oil:

36. • Meters the amount of fuel to
achieve desired power
• Regulates engine speed and
timing sequence
• Helps control emissions
Function of Fuel System

38. Fuel Delivery – History
• Pre-Combustion (PC)
• Direct Injection (DI)

39. MUI System
• A unit injector is positioned above each cylinder
• A mechanically actuated governor controls fuel rate (scroll metered )
• With flyweights and springs
• Timing is fixed

40. EUI Injector
• A unit injector is positioned above each
cylinder
• An Electronic Control Module (ECM)
controls fuel rate and timing
• Injectors are mechanically actuated by
a camshaft

41. EUI Injector
• Without pressure from the
rocker arm, a spring keeps the
plunger retracted
• Fuel flows into the injector
through the fill / spill port, past
the solenoid valve and into the
barrel

42. EUI - Injection
• On a single from the ECM,
the solenoid closes the
fuel valve
• Pressure elevates at the
tip to the 5,500 psi
needed to unseat the
valve
• Injection begins

43. EUI – Injection
• Fuel continues to inject until the
ECM signals the solenoid to open
the valve
• Injection timing and duration is
controlled by the ECM

44. HEUI System
• A unit injector is positioned above
each cylinder
• An Electric control module (ECM)
controls fuel rate , timing, and
injection position
• The injector is hydraulically actuated

45. Air System Operation
• Flow
• Precleaner
• Air Filters
• Turbochargers
• Intake Manifold and cylinder
head
• Combustion chamber
• Exhaust Manifold
• Wear
• Turbocharger
• Bearings
• seals

47. Electronics Control Module
Caterpillar's Electronic Control Module (ECM)
And sensors control and monitor key engine
function, including:
• Fuel temperature.
• Engine oil temperature.
• Oil pressure.
• Atmospheric pressure.
• Coolant temperature
• Injection actuation pressure
• Throttle position
• Injection timing & duration logged faults

48. Features & Benefits of Electronics
Features
o Electronics Engine Control
 Engine Speed Governing
 Torque Shaping
 Fuel-air Ratio Control
 Cold Mode Strategies
 Altitude Derating
 Fuel Temperature
Compensation
o Information Management
 Accurate Tracking
 Storage result
o Engine Monitoring
 Fluid Level
 Fluid Pressure
 Fluid Temperature

49. Benefits
• Improved Emissions
• Increased Performance &
Reliability
• Improved Diagnostics
• Meet customer needs for
New Features / Advanced
Technology